Appendix H - 33D4-6-670-1 (FATS).pdf

T.O. 33D4-6-670-1

1.2 SIGNIFICANT ITEM NUMBERS - • 400 through 540 - mechanical hardware (coded by size)

• 550 through 599 - mechanical hardware (not coded byDESCRIPTION.

size)

• 600 through 685 - electrical instrumentationThe test stand and adapter kit are each assigned a different

• 700 through 749 - electrical controls and conditionersset of significant item numbers (SIN). Significant item

• 750 through 765 - automation electronicsnumbers are assigned to assemblies, subassemblies, and

• 800 through 845 - electrical hardwarepiece parts as an aid in identifying and referring to those

• 905 through 950 - refrigerationitems. Any item that is assigned a SIN is referred to by that

SIN in text, tables, and illustrations throughout this manual.

1.3.2 Letters. The two letters in each SIN are selectedThe SIN is also referenced in the description column of the from letters A through Z, excluding I and O. The first letterIPB (T.O. 33D4-6-670-4).

classifies the major component with a part number. The second letter shows repeated usage of the item, usually1.3 TEST STAND - SIGNIFICANT ITEM starting with A. For instance, if five motor starters with theNUMBERS.

same part number are installed, the SIN are 705LA through 705LE. When the SIN is followed by -P, the component isEach SIN identifier consists of three digits and two letters.

on a control panel. When the SIN is followed by -S, theEach combination of digits and letters identifies the item.

component is on the sink. When the SIN is followed by -The first four characters of the SIN define a major compo- SP, the component is on the service panel.nent. The fifth character defines multiple usage of a like item. 1.4 ADAPTER KIT - SIGNIFICANT ITEM NUMBERS.1.3.1 Digits. The digits are assigned according to the type of equipment. Pressure transducers are (062 and 069).

Each SIN identifier consists of four digits and one letter.Check valves are (220). Motor starters are (705). The This combination applies only to adapter kit components.numeric range and function categories are as follows:

The same SIN is used when listing more than one item. For

• 020 through 150 - hydraulic and pneumatic instruments total quantity of an item used, check quantity column in

• 200 through 390 - hydraulic and pneumatic controls IPB.

and conditioners

Table 1-1. Units Under Test

Technical Order Title F101-GE-102 Engine

5E1-2-9-3 Overhaul, Central Integrated Test System Signal Processor

5E6-3-110-3 Overhaul with Parts Breakdown, Pyrometer

6J8-33-3 Overhaul, Main Fuel Nozzle

6J8-35-3 Overhaul, Augmenter Fuel Nozzles

6J15-7-56-3 Overhaul with Parts Breakdown, Augmenter Fuel Distributors

7J1-84-3 Overhaul with Parts Breakdown, Fuel/Oil Cooler

8A3-9-14-3 Overhaul, Augmenter-Fan-Temperature Control

9H2-7-36-3 Overhaul with Parts Breakdown, Inlet Guide Vane Actuator

9H2-7-37-3 Overhaul, Inlet Guide Vane Actuator

9H2-7-38-3 Overhaul with Parts Breakdown, Variable Stator Vane Actuator

F108-CF-100 Engine

2JA12-12-3 Overhaul Instructions, Turbine Clearance Nozzle

6J8-37-3 Overhaul Instructions, Fuel Nozzle

6J8-47-3 Overhaul Instructions, Fuel Nozzle (Textron)

6J24-10-3 Overhaul with Illustrated Parts Breakdown, Servo Fuel Heater

7J1-85-3 Overhaul with Illustrated Parts Breakdown, Oil/Fuel Heat Exchanger

9H2-7-39-3 Overhaul with Illustrated Parts Breakdown, Variable Stator Actuator

F110-GE-100 Engine

5E1-2-11-3 Overhaul, Engine Monitoring System Processor

1-3

Table 1-1. Units Under Test - Continued

Technical Order Title 5E1-2-12-3 Overhaul, Engine Monitoring System Computer

5E6-3-110-3 Overhaul with Parts Breakdown, Pyrometer

6J15-7-56-3 Overhaul with Parts Breakdown, Augmenter Fuel Distributors

6J8-33-3 Overhaul, Main Fuel Nozzle

6J8-35-3 Overhaul, Augmenter Fuel Nozzles

7J1-91-3 Overhaul with Parts Breakdown, Fuel/Oil Cooler

8A3-9-15-3 Overhaul, Augmenter-Fan-Temperature (AFT) Control

9H2-7-41-3 Overhaul with Parts Breakdown, Variable Stator Vane Actuator

9H2-7-42-3 Overhaul, Inlet Guide Vane Actuator

F110-GE-129 Engine

5E6-3-110-3 Overhaul with Illustrated Parts Breakdown, Pyrometer

6J8-33-3 Overhaul, Main Fuel Nozzle

6J8-35-3 Overhaul, Augmenter Fuel Nozzle

6J15-7-56-3 Overhaul with Illustrated Parts Breakdown, Augmenter Fuel Distributors

7J1-96-3 Overhaul with Illustrated Parts Breakdown, Tri-Cooler

8C3-19-2-3 Overhaul, Digital-Electronic-Control (DEC)

9H2-7-42-3 Overhaul, Inlet Guide Vane Actuator

9H2-7-44-3 Overhaul, with Illustrated Parts Breakdown, Variable Stator Actuator

F118-GE-100 Engine

2J-F118-3-10 Fuel Filter

5E1-2-16-3 Overhaul Instructions, Engine Monitoring System Processor

5E6-3-110-3 Overhaul with Parts Breakdown, Pyrometer

6J8-33-3 Overhaul, Main Fuel Nozzle

7J1-91-3 Overhaul with Parts Breakdown, Fuel/Oil Cooler

7J14-7-3 Overhaul with Illustrated Parts Breakdown, Oil Level/Temperature Sensor

8C3-9-4-3 Overhaul Instructions, Engine-Fan-Temperature (EFT) Control

9H2-7-41-3 Overhaul with Parts Breakdown, Variable Stator Vane Actuator

9H2-7-42-3 Overhaul, Inlet Guide Vane Actuator

1.5 TEST STAND - DESCRIPTION. 1.6.1 Section A. Section A contains the vertical aug-menter fuel manifold test sink, a control panel for proof

The test stand (Figure 1-1) is made up of four sections and pressure testing, spray chamber (552KB), Micro-Flo 100 an adapter kit. A remote electrical control cabinet and a (602DA), and a workbench. A utility drawer is provided in remote 50-HP reduced voltage motor-starter cabinet are the work bench. Two flowmeter signal conditioner racks, included with the major assemblies of the test stand. the purge box differential pressure gage panel, and elec-tronics for spray chamber (552KB) are inside this section.

1.6 TEST STAND ASSEMBLY.

1.6.2 Section B. Section B contains high-pressure pump

The test stand assembly (Figure 1-1) consists of sections A, (346NA), return heat exchanger (329SA), spray chamber B, C, and D, bolted together to form an L-shaped structure. (552KA), Micro- Flo 100 (602CA), and water sinks. All The four sections are designed for operation in a Class I, supply and return fuel conditioning equipment, instrumen- Division 1, Group D hazardous area, with ambient tempera- tation, and shop air and water conditioning and distribution tures between 45 and 110°F. Each section is a monocoque equipment are in this section. A gas bottle rack is mounted framework mounted on a channel base. The test stand is at the rear, containing four CO2 bottles and a nitrogen enclosed and has removable, hinged doors on the sides and bottle. The service connection panel is next to the gas bottle back. Primary controls for test stand operation are on the rack.

front panels of sections B and C.

1-4

1.6.3 Section C. Section C contains the following 1.8 WALL-MOUNTED MOTOR STARTER.

components:

The 50-HP motor starter (705HA) (Figure 1-1) for the low-

• Boost pump (348EA) pressure fuel supply pump is housed in a NEMA type 1

• 400-gallon fuel tank (552DA) box. It is mounted on the wall close to the electrical control

• Inlet guide vane (IGV) actuator control panel cabinet.

• Low-pressure pump (349RA)

1.9 ADAPTER KIT.• Purge boxes

• Service panel

The adapter kit includes tools, fixtures, hoses, and fittings• Shop air hose required to test the UUT. Refer to TO 33D4-6-670-4 for• Supply filters illustration and list of kit components.• Test stand and pump control stations

1.10 LEADING PARTICULARS.1.6.4 Section D. Section D, which includes the main fuel sink, is bolted to the front of section B.

Refer to Table 1-2 for leading particulars of the fuel accessory test stand.1.7 REMOTE ELECTRICAL CONTROL CABINET.

1.11 CONSUMABLE MATERIALS.The remote electrical control cabinet is a National Electri-cal Manufacturer Association (NEMA) type 1 enclosure.

Consumable materials required to maintain the test standThe cabinet has full-length double doors in each side for are listed in Table 1-3.access to internal components. Electrical connections between the cabinet, test stand, and motor starter are made 1.12 REFERENCED PUBLICATIONS.

through conduit to terminal strips in explosion-proof junc-tion boxes. The 480-volt, 60-Hz, 3-phase power is routed to Publications referenced in this manual are listed in the cabinet bus for system operation. A stepdown trans- Table 1-4.

former in the cabinet provides 110-volt, 60-Hz, single-phase power for operation of electrical controls in the test 1.13 ABBREVIATIONS AND SYMBOLS.

stand. The cabinet houses the fuses, control transformer, control relays, and motor starters (705JA, 705JB, 705KA, Standard abbreviations used in this manual are found in and 705QA). These starters operate high-pressure pump MIL-STD-12. Symbols and nonstandard abbreviations are (346NA), boost pump (348EA), and purge box fans listed in Table 1-5.

(591AA and 591AB).

Table 1-2. Leading Particulars

Component/Service Requirements/Specifications Air System

Air tools supply adapter (530AH) 0-90 PSIG

Test stand blow gun adapter (557BA) 0-29 PSIG

Dimensions

Motor starter cabinet

Depth 11 inches

Height 52 inches

Width 36 inches

Remote electrical control cabinet

Depth 26 inches

Height 72 inches

Width 52 inches

Test stand

Depth 168 inches

Height 84 inches

Width 336 inches

Fuel System

1-5

Table 1-2. Leading Particulars - Continued

Component/Service Requirements/Specifications Fluid flow 0-90,000 PPH

Fluid pressure 0-2500 PSIG

Fluid temperature 85±10°F

Fluid type MIL-C-7024

Return ports

Metered orifice return adapters (532CC, 532CD, 10.5-190 PPH at 1000 PSIG maxi- 532CE, and 532CF) mum

Supply return adapters (532CG and 532CH) 0-1500 PSIG

Unrestricted return adapters (530AC, 538AA, and Minimum backpressure

532CJ)

Supply ports

Metered supply adapters (532CB, 532CL, and 532CP) 2.7-3600 PPH at 0-1500 PSIG

Metered supply adapter (534AB) 170-24,700 PPH at 0-125 PSIG

Metered supply adapter (538AB) 800-90,000 PPH at 0-100 PSIG

Proof-pressure adapters (530AB and 530AC) 0-2250 PSIG

Proof-pressure adapters (530AD, 530AE, 531AA, 0-2260 PSIG 531AB, 532CM, and 532CN)

Instrumentation

Differential pressure gages (071AA through 071AF)

Range 0-50 PSID

Accuracy ±2-5% of full scale

Differential pressure gages (071FA through 071FF)

Range 0-2 inches of water

Accuracy ±2-3% of full scale

Digital multimeter (655CA)

Range (usable) 0.0 mV to 20.0 VAC

Accuracy ±0.25 VAC

Flowmeters

10.5-205.0 PPH (021FA through 021FD) ±0.25% of reading

170-24700 PPH (024AA) ±0.25% of reading

2.7-5.0 PPH (021AA through 021AD) ±0.25% of reading

35.5-3600 PPH (022DA through 022DD) ±0.25% of reading

800-118000 PPH (028AA) ±0.25% of reading

Flow transducers

0.20 SCFM (054AA) ±1.0% of full scale

0.70 SCFM (050AA) ±1.0% of full scale

Micro-Flo 100 instrumentation systems (602CA and 602DA)

Liquid flow indication

Accuracy (LFC6 - series meters) ±0.55% of reading

Accuracy (ANC - series meters) ±0.3% of reading

Range Flowmeter dependent

Pressure indication loop

Accuracy ±0.5% of full scale

Range Transducer dependent

1-6

Component/Service Requirements/Specifications Temperature indication circuits

Accuracy ±1.0°F

Range -100 to +400°F

Pressure gage (072KA)

Accuracy ±0.5% of full scale

Range 0-160 PSIG

Pressure gage (072UA)

Accuracy ±0.5% of full scale

Range 0-100 PSIG

Pressure gages (079KA and 079KD)

Accuracy ±30 PSIG

Range 0-3000 PSIG

Pressure gages (079UA and 079UB)

Accuracy ±30 PSIG

Range 0-3000 PSIG

Temperature gages (077BA and 077BB)

Accuracy ±1.0% of full scale

Range 20 to 240°F

Temperature indicator (649AA)

Accuracy ±1°F

Range -328 to +752°F

Thermocouples

-300 to +700°F ±1.5°F of reading

Timer counter (644CA)

Accuracy ±3 seconds for 10 minutes

Range 0 to 9 minutes, 59 seconds

Pressure transducers

0-15 PSIG (062RA) ±0.1% of full scale

0-50 PSID (061HA) ±0.1% of full scale

0-50 PSIG (062HA, 062HB, and 062HC) ±0.1% of full scale

0-100 PSIG (062JA and 062JB) ±0.1% of full scale

0-200 PSID (061PA) ±0.1% of full scale

0-200 PSIG (062SB, 062SC, and 062SD) ±0.1% of full scale

0-225 PSIG (069EA) ±0.1% of full scale

0-500 PSIG (062NA) ±0.1% of full scale

0-750 PSID (061UA) ±0.1% of full scale

0-1000 PSIG (062PC) ±0.1% of full scale

0-1150 PSIG (062QA and 062QB) ±0.1% of full scale

0-5000 PSID (062LA) ±0.1% of full scale

Spray chambers (552KA and 552KB)

Spray angle indication

Accuracy ±0.5% of reading

Flow

Range 0-100% of master orifice flow

1-7

Component/Service Requirements/Specifications Accuracy ±0.5% of reading

Range 50-145 degrees arc

X-Y recorder (708JA) with time base

Range

X axis 0-10 inches

Y axis 0-7 inches

Accuracy

X axis ±0.02 inch

Y axis ±0.014 inch

Motor Specifications

Boost (centrifugal) pump (348EA) motor 5 HP, 3600 RPM, 480 volt, 60 Hz, 3 phase

High-pressure pump (AC motor (701RA) 30 HP, 3600 RPM, 480 volt, 60 Hz, 3 phase

Low-pressure (vertical) pump motor (349RA) 5 HP, 3600 RPM, 480 volt, 60 Hz, 3 phase

Purge box fan (591AA and 591AB) motors 0.5 HP, 3600 RPM, 480 volt, 60 Hz, 3 phase

Nitrogen System

Nitrogen static supply adapter (531AA) 0-500 PSIG

Pump Specifications

Collection tank return [part of spray chamber (552KA)] 9 GPM at 30 PSIG

Gear (high-pressure fuel supply) pump (346NA) 25 GPM at 1600 PSIG

Proof-pressure (air-driven) pumps (340BA and 340BB) 0-2500 PSIG maximum

Upright centrifugal (boost) pump (348EA) 30 GPM at 50 PSIG

Vertical (low-pressure fuel supply) pump (349RA) 100 GPM at 165 PSIG, 250 GPM at

150 PSIG

Services Required

Drip pan drain (3) Facility waste reservoir

Purge fan inlet * 200 SCFM maximum

Shop air supply [bezel (413AA)] 130 SCFM at 90-125 PSIG

Sink drain [bezel (414AB)] 1 gallon per day

Sink exhaust (2) * 40 SCFM at 0.5 inch of water vacu-um

Spray chamber exhaust 100 SCFM at 0.5 inch of water vac-uum

Tank drain 100 GPM

Test stand ventilation (3) * 100 SCFM at 0.5 inch of water vac-uum

Water return port [bezel (418AB)] 50 GPM at 30 PSIG maximum back-pressure

Water supply port [bezel (418AA)] 50 GPM at 40-70 PSIG, 70°F maxi-mum

Water System Requirements

Water fill adapter (532CK) 0-10 GPM at 1000 PSIG maximum

* These exhaust ducts to be manifolded on top of stand and routed to facility suction blower.

1-8

Table 1-3. Consumable Materials

Specification Nomenclature or Part Number CAGE General Use

Barrier material, water-vapor MIL-B-121, C1 1 - - Packing test stand for shipment proof

- -Calibrating fluid, aircraft fuel MIL-C-7024, Type II Test fluid for test stand system components

Cloth, lint-free CCC-C-46D - - General cleaning of components

Cleaner, general purpose P-D-1747 - - Cleaning test stand surfaces

Grease, general purpose MIL-G-23827B - - Lubricate pump bearings

Grease, pressure MIL-G-81322D - - Lubricate motor bearings through pressure fittings

Oil, lubricating MIL-L-6081C, SAE 20W - - Lubricate drive gearbox

Petrolatum VV-P-236 Lubricate flowmeter threads

Table 1-4. Referenced Publications

Publication Title AFOSH STD 127-66 Air Force Occupational Safety and Health Standards

MIL-STD-12 Abbreviations for Use on Drawings, and in Specifications, Standards and Technical Documents

TO 00-25-233 Integrated Pressure Systems and Components

TO 00-25-234 General Shop Practice Requirements for the Repair, Maintenance and Test of Elec-trical Equipment

TO 1-1-1 Cleaning of Aerospace Equipment

TO 33D4-6-670-4 Illustrated Parts Breakdown, Fuel Accessory Test Stand

TO 33K1-4-1828-1 X-Y Recorder Calibration Procedure

TO 33K6-4-1083-1 Calibration Procedure, Turbine Flowmeter with Signal Conditioner ANC8-4

TO 33K6-4-60-1 Calibration Procedure, Turbine Flowmeter LF6

TO 33K6-4-889-1 Calibration Procedures for Dial Indicators (All Types and Styles)

TO 33K8-4-120-1 Calibration Procedure for Digital Multimeter 8840A (Fluke)

1-9

Table 1-5. Symbols and Nonstandard Abbreviations Table 1-5. Symbols and Nonstandard Abbreviations - Continued

Symbol/ Symbol/ Abbreviation Definition Abbreviation Definition °C Degrees Celsius Hz Hertz °F Degrees Fahrenheit IGVA Inlet Guide Vane Actuator

* Enter key (used on Micro-Flo 100 kVA Kilovolt amperes keyboard) Kohm Kilo ohm = Equal LH Left hand

- Minus LVDT Linear Variable Differential Trans- % Percent former + Plus NEC National Electrical Code ± Plus or minus NEMA National Electrical Manufacturers’

Associationx Times (multiplication) No. Number: To (ratio) PPH Pounds per hourA/D Analog-to-digital PSID Pounds per square inch differentialAFT Augmenter fan temperature RH Right handCO2 Carbon dioxide RVDT Rotary Variable Differential Trans-CAGE Commercial and Government Entity formerDEC Digital electronic control SCIM Standard cubic inch per minuteDMM Digital multimeter SCFM Standard cubic feet per minuteEFT Engine fan temperature SIN Significant item numberEXT Exit SSM Servo system moduleHg Mercury VSV Variable Stator VaneHI High

1-10

CHAPTER 2

SPECIAL TOOLS AND TEST EQUIPMENT

2.1 INTRODUCTION. test stand. An equivalent item may be used if the recom-mended test equipment is not available.

This chapter contains special tools and test equipment

2.3 SPECIAL TOOLS AND TEST EQUIPMENT -required for operation, maintenance, and calibration of the test stand. FABRICATION.

2.2 SPECIAL TOOLS AND TEST EQUIPMENT. A thermocouple cable is used during calibration of temper-ature measurement circuits. Order thermocouple cable from

The special tool required consists of a locally fabricated Omega Engineering Inc., PO Box 4047, Stamford, CT thermocouple cable (Figure 2-1). Table 2-1 lists test equip- 06907-0047, or fabricate as follows:

ment required for calibration and maintenance of test stand instrumentation. This equipment is not supplied with the a. Obtain parts listed in Figure 2-1.

b. Connect wires (TO 00-25-234).

LEGEND

1. Connector, Male, Type T (O5T-MQ), 1 Each

2. Wire, Type T (EXPP-T-205), 30 Feet

Figure 2-1. Thermocouple Cable - Fabrication

2-1

Table 2-1. Test Equipment

Model No. Nomenclature Accuracy Use and application AT-60 Flow Technology Aerotrak gas ±0.02% of reading Calibration of air flowmeters flow calibrator

AT-8 Flow Technology Aerotrak gas ±0.02% of reading Calibration of air flowmeters flow calibrator

10-10525 Mansfield and Green deadweight ±0.1% of reading Calibration of pressure transducers tester

2190A/Y2003 Fluke thermocouple calibrator ±0.46°F Simulated thermocouple signal

2213A Tektronix Oscilloscope ±3% of reading Voltage gain adjustment for Pegasus controller

311AHT Cox liquid flowmeter calibrator ±0.15% repeatability Calibration of turbine flowmeters

3325A Hewlett Packard precision fre- ±0.03% of reading Calibration of Micro-Flo 100 quency generator

334A Hewlett Packard distortion ana- ±0.2% of reading Adjustment of linear variable differ-lyzer ential transducer (LVDT) gain and calibration of inlet guide vane actua-tor (IGVA) control system

343A Fluke voltage calibrator -- --

6716000-5 * Parker Hannifin quick-connect -- Calibration of spray angle adapter

6835006-64 * Parker Hannifin gage blocks 0.6 and 0.1 Calibration of spray angle

6836016 * Parker Hannifin master angle -- Calibration of patternator collector calibrator tubes

6856014-1 * Parker Hannifin restrictor orifice -- Calibration of patternator collector tube

6856014-2 * Parker Hannifin restrictor orifice -- Calibration of patternator collector tube

7250A Fluke universal counter ±0.001 second Calibration of timer counter

77 Princo thermometer set ±0.2°C Calibration of thermocouples

7780-20 Ashcroft digital pressure indica- ±0.01 PSIG Calibration of pressure loop tor

7780-50 Ashcroft digital pressure indica- ±0.025 PSIG Calibration of pressure loop tor

7780-1000 Ashcroft digital pressure indica- ±0.05 PSIG Calibration of pressure loop tor

8500A Fluke digital voltmeter ±0.0006% of reading Verification of power supply

8840A/AF Fluke digital multimeter ±0.0006% of reading Calibration of spray angle

8909-524 Fixed rotary variable differential -- Adjustment of linear variable differ-transformer (RVDT) ential transformer (LVDT) gain

8909-526 Fixed rotary variable differential -- Adjustment of linear variable differ-transformer (RVDT) ential transformer (LVDT) gain

2-2

Table 2-1. Test Equipment - Continued

Model No. Nomenclature Accuracy Use and application BS3060-1 Wiring adapter, F101 PLA/MVT -- Adjustment of linear variable differ-ential transformer (LVDT) gain

BS3060-2 Wiring adapter, F108 PLA -- Adjustment of linear variable differ-ential transformer (LVDT) gain

BS3060-3 Wiring adapter, F110 VSV -- Adjustment of linear variable differ-ential transformer (LVDT) gain

BS3060-4 Wiring adapter, F110 A8 -- Adjustment of linear variable differ-ential transformer (LVDT) gain

BS3060-5 Fixed angle RVDT calibration -- Adjustment of linear variable differ-ential transformer (LVDT) gain

913AC1 Rosemount temperature calibra- ±0.2°F Thermocouple troubleshooting tion bath

* Part of spray chambers (552KA and 552KB)

2-3/(2-4 blank)

CHAPTER 3

PREPARATION FOR USE AND SHIPMENT

3.1 INTRODUCTION. b. Remove barrier material.

c. Inspect for the following:This chapter contains instructions for unpacking and pre-paring the test stand for use, and preparing it for shipment

(1) All items on shipping list are accounted for.or storage.

(2) Frame is not bent, sprung, or otherwise3.2 PREPARATION FOR USE.

damaged.

The test stand is shipped in seven sections. Each section is (3) Glass is not broken.

wrapped with water-vapor proof barrier material, MIL-B- 121, to prevent contamination. It is then completely (4) Instruments are not damaged.

enclosed in a wooden shipping crate and mounted on a shipping skid. Loose items are packed in cartons and stored (5) Piping and tubing are securely mounted and inside test stand during shipping. undamaged.

3.3 INSTALLATION FACILITIES. (6) Controls and valves operate freely, but without excessive looseness.

The test stand is built in accordance with National Electri-

(7) Major equipment is securely mounted.cal Code (NEC) Class 1, Division 1, Group D hazardous area requirements. It shall be installed in an area that is

d. Move test stand sections into place, using forkliftadequately protected against the hazards of volatile fuels channels.and vapors. The remote electrical control cabinet and the motor starter cabinet shall be installed in nonhazardous

e. Level sections when in place.areas.

f. Align sections and bolt together.3.4 INSTALLATION REQUIREMENTS.

Test stand installation requirements are as follows: WARNING

3.4.1 The test stand requires about 168 by 336 inches of

floor space with enough work space for maintenance and The electrical control cabinet and 50-HP motor operation. starter cabinet are not designed for use in an explosive atmosphere. Do not install nor oper-

3.4.2 The electrical control cabinet requires about 26 by ate these cabinets where explosive conditions 52 inches of floor space with enough work space for exist. Installation or operation of this equip-maintenance and operation. ment in an explosive atmosphere can cause fire or explosion resulting in injury or death to3.4.3 The motor starter cabinet requires about 36 by 52 personnel.inches of floor space with enough work space for mainte-nance and operation. The cabinet is mounted on the wall g. Place remote electrical cabinet and motor starter and should be near the electrical control cabinet. cabinet in permanent locations, no more than 200 feet from the test stand.3.5 UNPACKING AND LOCATING.

3.6 SERVICE CONNECTIONS.

Unpack and provide locations for test stand components as follows: Connect facility services, with exception of ventilation, electrical, nitrogen, and CO2 bottles at service connection panel on rear of test stand. Table 3-1 lists these connectionsCAUTION and connector sizes. Service connections are shown in Figure 3-1.

Take care in unpacking the test stand to prevent damage to finish, instruments, and loose parts.

a. Remove top and sides of shipping crates, leaving the sections on skids.

3-1

Table 3-1. Service Connections

SIN Service type Connection size

- - Electrical enclosure purge air (2) 4-inch ducts

- - Drip pan drains (3) 1-inch NPT

- - Purge fan inlets (2) 4-inch ducts

- - Sink exhausts (2) 4-inch ducts

- - Spray chamber exhausts (2) 3-inch ducts

- - Test stand ventilation (3) 8-inch ducts

411BA Nitrogen cylinder supply 3/8-inch NPT

413AA Shop air supply 3/4-inch NPT

414AA Fuel tank pressure fill 1-inch NPT

414AB Sink drain 1-inch NPT

414AC Spray chamber 1 tank vent 1-inch FNPT

414AD Spray chamber 2 tank vent 1-inch FNPT

418AA Water supply 2-inch NPT

418AB Water return 2-inch NPT

418AE Fuel tank vent 2-inch NPT

419FA Fuel tank drain 4-inch NPT

822AA Ground stud, section A 1/2-13UNC

822AB Ground stud, section B 1/2-13UNC

822AC Ground stud, section C 1/2-13UNC

822AD Ground stud, section D 1/2-13UNC

822AE Ground stud, remote electrical cabinet 1/2-13UNC

3.7 AIR AND WATER REQUIREMENTS. b. Drain for waste fuel from sinks and the 10-gallon fuel collection tank.

Provide the following:

c. Three drip pan drains, one each for sections A, B,

a. Shop air supply of 90-125 PSIG at 250 SCFM. and C.

b. A 2000-PSI dry nitrogen bottle at rear of section B. 3.9 VENTILATION REQUIREMENTS.

c. Cold water supply of 50 GPM at 40-70 PSIG, 70°F Make the following ventilation connections:

maximum.

a. Exhaust manifold providing vacuum of 0.5-inch for

d. Drain for cold water return from heat exchanger ventilation ducts from sinks and sections A, B, and with minimum back pressure of 30 PSIG. C.

3.8 FUEL REQUIREMENTS. b. Exhaust for spray chamber ventilation ducts.

Connect fuel supply and drains as follows: c. Fresh air for electrical system purge boxes A through D.

WARNING 3.10 ELECTRICAL REQUIREMENTS.

Route test stand interconnecting wiring from remote cabi- Fuel and drain lines are equipped with traps nets through roof panels of the test stand. Wires and and flame arresters conforming to local fire conduit for connecting sections of the test stand are protection codes. Do not operate test stand supplied.

without these devices in place and operational.

a. Provide the following:

a. Fill and drain provisions for 400-gallon fuel tank.

3-2

c. Disconnect fuel tank fill lines and drip pan drains.

WARNING

d. Disconnect 8-inch exhaust duct.

• Electrical power shall be off before connect- NOTE ing or disconnecting electrical connectors.

Electricity causes shock, burns, and death. The following step is not necessary if the test stand is only being moved within its present• Improperly grounded electrical equipment facility.can cause severe shock or death. Equipment shall be properly grounded before use. e. Check that all items listed on original shipping document are accounted for.(1) 480-volt, 60-Hz, 3-phase (76-kVA), facility power. f. Install blocks, straps, holddown bolts, and packings on pumps, drive motors, pressure gages, relays,(2) Facility absolute zero potential electrical motor starters, and instruments, as required.ground.

g. Tag and disconnect interconnecting hoses betweenb. Refer to Chapter 6 wiring diagrams to make proper test stand sections.connections between test stand and remote cabinets and between remote drive cabinet and facility h. Disconnect ground straps and remove mounting ground. bolts joining sections A, B, C, and D.

c. Check continuity and ground before connecting i. If test stand will be shipped or stored, pack loose wires. items carefully in cartons. Store cartons inside test stand.d. Connect all sections of the test stand and remote cabinets to an external facility earth ground system. j. Using a forklift, separate the four sections.

3.11 PREPARATION FOR SHIPMENT. k. Secure all doors and panels, and wrap sections in flexible barrier material, MIL-B-121.

Prepare the test stand for shipment as follows:

l. Pack test stand sections in wooden shipping crates

a. Remove all power from test stand and disconnect on skids appropriate to shipping requirements.

power and ground connections.

b. Turn off and disconnect service connections listed in Table 3-1 at service connection panel (Figure 3-1).

3-3

LEGEND

1. Water Return (418AB) 4. Sink Drain (414AB)

2. Water Supply (481AA) 5. Fuel Tank Drain (419FA)

3. Shop Air (413AA) 6. Fuel Tank Pressure Fill (414AA)

Figure 3-1. Service Connections

3-4

CHAPTER 4

OPERATION INSTRUCTIONS

4.1 INTRODUCTION. 4.2 CONTROLS AND INDICATORS.

This chapter contains a description of controls and indica- Table 4-1 lists the panel-mounted controls and indicators tors, theory of operation, safety features, and operating and their functions. Figure 4-1 shows locations of all procedures for the test stand. panels. Each control and instrument is referenced to an illustration (Figure 4-2 through Figure 4-14).

Table 4-1. Controls and Indicators

Index No. Nomenclature Function

Pressure Switch Panel (Figure 4-14)

1. Differential pressure gage Displays differential pressure across pressure switch (721ZB) for purge box

(071FA) C

2. Differential pressure gage Displays differential pressure across pressure switch (721ZC) for purge box

(071FB) D

3. Differential pressure gage Displays differential pressure across pressure switch (721ZD) for transducer (071FC) purge box (001LB)

4. Differential pressure gage Displays differential pressure across pressure switch (721ZA) for (071FD) X-Y recorder purge box

5. Differential pressure gage Displays differential pressure across pressure switch (721ZE) for purge box

(071FE) G

6. Differential pressure gage Displays differential pressure across pressure switch (721ZF) for transducer (071FF) purge box (001MA)

Service Panel (Figure 4-13)

1. Temperature gage (077BA) Displays inlet temperature at water supply strainer (358BA)

2. Temperature gage (077BB) Displays water temperature at water return port [bezel (418AB)] on service connection panel

3. Differential pressure gage Displays air supply pressure in air tank (550BA)

(072KA)

4. 16-channel annunciator Indicates abnormal conditions detected by signals from pressure, tempera- (734GA) ture, and level switches

5. Elapsed timer (644BA) Displays elapsed operating time of low-pressure pump (349RA)

6. Elapsed timer (644BB) Displays elapsed operating time of boost pump (348EA)

7. Toggle valve (210CA) Bleeds air from filter (319NA)

8. Motor starter switch Provides 120-VAC control power to control relay (711AK) and operator (720AB) station (733CA) on panel L

9. Motor starter switch Provides 120 VAC through limit switches (724CA, 724CB, 724CC) and (720AA) contactor (711JA) to light fixtures (813HA, 813HD, 813HE, 813HF, 813HG, and 813HH)

10. Bleed flow indicator Displays air bubbles when toggle valve (210CA) opens line from filter

(110AA) (319NA)

11. Phone jack (801SB) Provides communications link between remote electrical cabinet and test stand

12. Differential pressure gage Displays differential pressure across filter (313EB)

(071AE)

4-1

Table 4-1. Controls and Indicators - Continued

Index No. Nomenclature Function

13. Differential pressure gage Displays differential pressure across filter (313EC) for discharge from col- (071AF) lection tank in spray chamber (552KA)

14. Differential pressure gage Displays differential pressure across filter (316SB) for output of high-pres- (071AC) sure pump (346NA)

15. Differential pressure gage Displays differential pressure across filter (316SA) for output of boost (071AD) pump (348EA)

16. Differential pressure gage Displays differential pressure across filters (316CA and 316DA) for shop (071AA) air supply

17. Differential pressure gage Displays differential pressure across filter (319NA) for low-pressure pump

(071AB) (349RA)

18. Pressure gage (072UA) Displays pressure of facility water supply at inlet of strainer (358BA)

Panel N (Figure 4-2)

1. Pressure gage (079UB) Displays high pressure at pressure tap adapter (530AD) and proof-pressure supply adapters (530AE, 531AA, 531AB, 532CM, and 532CN) in main sink

2. Adapter (530AP) Provides calibration port for pressure gage (079UB)

3. Pressure gage (079KB) Displays discharge pressure of air-driven fuel pump (340BB)

4. Air pressure regulator Regulates 90-pounds per square inch gage (PSIG) air pressure for setting air (290DB) driven pump (340BB)

5. Pressure regulator (250FB) Regulates pressure through filter (311BB) to pressure tap adapter (530AD) and proof-pressure supply adapters (530AE, 531AA, 531AB, 532CM, and 532CN) in main sink

6. Ball valve (200CB) Shuts off high-pressure supply to pressure tap adapter (530AD) and proof-pressure supply adapters (530AE, 531AA, 531AB, 532CM, and 532CN) in main sink

7. Needle valve (240DC) Shuts off 90-PSIG air supply to air tool adapter (530AH)

8. Adapter (530AH) Provides hose connection through needle valve (240DC) and 90-PSIG air supply

Panel R (Figure 4-3)

1. Toggle valve (210CV) Bleeds air from pressure transducer (062SD)

2. Needle valve (242GH) Shuts off high-pressure supply to adapter (532CR) for spray chamber No. 2

3. Ball valve (202BD) Shuts off high-pressure supply to adapter (532CQ) for spray chamber No. 1

4. Toggle valve (210CU) Bleeds air from adapter (539BU) and transducers (062HC, 062PC, and

062SC)

5. Bleed flow indicator Displays air bubbles when toggle valve (210CU) opens line from adapter (110AN) (539BU) and transducers (062HC, 062PC, and 062SC)

6. Adapter (539BU) Connects transducer (062PC) through ball valve (200LC) to transducer (062SC) and through gage saver (390ED) to transducer (062HC)

7. Adapter (532CQ) Hose connection for high-pressure supply to spray chamber No. 1

8. Adapter (532CR) Hose connection for high-pressure supply to spray chamber No. 2

9. Adapter (539BV) Connects hose to transducer (062SD)

10. Bleed flow indicator Displays air bubbles when toggle valve (210CV) opens line from transducer (110AP) (062SD) and adapter (539BV)

Panel S (Figure 4-4)

1. 5100 series mini-enclosure Controls servo valve (236BB) to provide stable fluid supply to spray cham- (servo control system) ber supply No. 2 at adapter (532CR) and spray chamber supply No.1 adapt- (713ZB) er (532CQ) on panel R

4-2

Index No. Nomenclature Function

2. Timer counter (644CB) Used for unit under test (UUT) timed tests

3. Temperature indicator Displays temperatures at inlet and outlet of heat exchanger (322CB) and in (649EA) transducer purge box (001MA)

4. Indicating lamp (814ED) Green lamp lights when power is supplied to spray chamber (552KB) through power switch (725AB)

5. Switch (725AB) Provides 120-VAC to spray chamber (552KB)

6. Potentiometers (820TK, Provides proportionate voltage through selector switch (726NB) to excite 820TL, 820TM, 820TN, pulse internal modulation (PIM) input of servo control system (713ZB)

820TP, 820TQ, 820TR,

820TS, and 820TT)

7. Selector switch (726NB) Selects one of nine potentiometers (820TK, 820TL, 820TM, 820TN, 820TP, 820TQ, 820TR, 820TS, or 820TT) for voltage input to servo control system

(713ZB)

8. Pushbutton switch (730BC) Provides for emergency shutdown of test stand. Removes all power and disables all control circuits, except to inside lights and fire protection sys-tem

9. Micro-Flo 100 system Monitors and displays test pressures, flows, and temperatures

(602DA)

Panel E (Figure 4-5)

1. Pressure gage (079KE) Displays output high-pressure fuel supply at servo valve (236BB)

2. Ball valve (202BB) Shuts off cooling fluid flow through heat exchanger (322CB)

3. Needle valve (240DA) Shuts off nitrogen static supply to adapter (530AA) in main sink

4. Regulator valve (290RA) Regulates nitrogen supply pressure through shutoff valve (240DA) to static supply adapter (530AA in main sink

5. Needle valve (240DB) Bleeds nitrogen static supply adapter (530AA) through muffler (460AA)

6. Adapter (539BS) Connects nitrogen or air hose to transducer (062RA) through needle valve (249LR), transducer (062NA), and gage saver (390EC)

7. Needle valve (249LR) Connects transducer (062RA) and 0-500 PSIG transducer (062NA) to adapt-er (539BC) on panel J

8. Needle valve (242GD) Controls water supply to adapter (532CK) in water sink

9. CO2 fire protection system Manual release handle for activating CO2 fire protection system temperature controller

(369AA)

Panel F (Figure 4-6)

1. Needle valve (242GG) Shuts off high-pressure supply for spray chamber supply No. 2 adapter (532CP) on this panel

2. Ball valve (202BC) Shuts off high-pressure supply to adapter (532CL) for spray chamber No. 1

3. Adapter (530AJ) Hose connection for nozzle inlet pressure No. 1 supply and adapter (530AK) in main sink

4. Adapter (532CL) Hose connection for high-pressure supply to spray chamber supply No. 1

5. Adapter (532CP) Hose connection for high-pressure supply to spray chamber supply No. 2

6. Adapter (530AM) Hose connection to nozzle inlet pressure No. 2 port and nozzle pressure at adapter (530AN) in main sink

Panel G (Figure 4-7)

4-3

Index No. Nomenclature Function

1. 5100 series mini-enclosure Provides stable high-pressure fluid supply for nozzle and inlet guide vane (713ZA) actuator (IGVA) testing. Controls operation of servo valve (236BA), based on feedback received from transducers (062VA and 062WA) and setting of potentiometers (820TA, 820TB, 820TC, 820TD, 820TE, 820TF, 820TG, 820TH, and 820TJ)

2. Timer counter (644CA) Used for timed UUT tests

3. Temperature indicator Displays temperatures at transducer purge box (001LB), low-pressure fluid (649AA) supply temperature switch (722JB), boost pressure supply temperature switch (722JC), inlet of heat exchanger (329SA), and inlet and outlet of heat exchanger (322CA)

4. Potentiometers (820TA, Provides proportionate voltage through selector switch (726NA) to excite 820TB, 820TC, 820TD, PIM input of servo control system (713ZA)

820TE, 820TF, 820TG,

820TH, and 820TJ)

5. Selector switch (726NA) Selects one of nine potentiometers (820TA, 820TB, 820TC, 820TD, 820TE, 820TF, 820TG, 820TH, or 820TJ), for input voltage to servo control system

(713ZA)

6. Micro-Flo 100 system Monitors and displays test pressures, flows, and temperatures

(602CA)

7. Pushbutton switch (730BA) Provides for emergency shutdown of test stand. Removes all power and disables all circuits, except inside lights and fire protection system

Panel H (Figure 4-8)

1. Pressure gage (079KC) Displays outlet pressure of high-pressure fuel supply servo valve (236BA)

2. Thermocouple probe Provides ambient air temperature to Micro-Flo 100 (602CA) on panel G

(090DA)

3. Needle valve (242GE) Shuts off high-pressure supply inlet pressure to selector valve (272ZA) of supply/return adapters (532CG and 532CH) in main sink

4. Pressure gage (079UA) Displays fluid pressure at calibration adapter (530AL) and through needle valve (240PP) at pressure tap adapter (530AC) and proof-pressure supply adapter (530AB) in main sink

5. Adapter (530AL) Calibration port for pressure gage (079UA)

6. Pressure gage (079KA) Displays output pressure of air-driven fuel pump (340BA)

7. Ball valve (200CA) Provides shutoff for proof-pressure supply adapter (530AB) and pressure tap adapter (530AC), both in main sink

8. Pressure regulator (250FA) Regulates fluid pressure to proof-pressure supply adapter (530AB) and pres-sure tap adapter (530AC), both in main sink

9. Receptacle (809AA) Provides electrical interface to IGVA test fixture. Routes actuator excitation, position, velocity, and feedback signals to control system (735AA) on panel L

10. Air pressure regulator Regulates 90-PSIG air supply pressure at input of air-driven fuel pump (290DA) (340BA) to control discharge pressure

11. Needle valve (242GB) Provides fine adjustment of fluid flow from output of flow control valve (238YA) and bypass needle valve (242GA) to supply clamp adapter assem-bly (539KB) in main sink

12. Needle valve (242GA) Provides fine adjustment for bypass of fluid flow around control valve

(238YA)

13. Receptacle (811QA) Provides electrical interface to VSV actuator test. Provides excitation volt-age and LVDT feedback voltage

4-4

Index No. Nomenclature Function

14. Air pressure regulator Regulates 90-PSIG air supply pressure for flow control valve (238YA) (290CA) setting

15. Needle valve (244AA) Controls low-pressure supply for metered supply adapter (534AB) in main sink

16. Needle valve (242GC) Provides fine bypass adjustment of low-pressure supply to supply adapter (534AB) in main sink

17. Ball valve (270BA) 90-PSIG air supply shutoff for air flow through ball valve (274JA) permit-ting sink to drain through port (bezel (414AB)) on service connection panel

18. Relief valve (260DA) Sets system pressure by controlling bypass return through relief valve (266BA). Relief valve (260DA) discharges directly to tank (552DA)

19. Selector valve (272GA) Routes discharge fluid flow from servo valve (236BA) to return adapters (532CG and 532CH) with no measurement or to supply adapter (532BA) in main sink and adapters (532CL and 532CP) on panel F with flow measure-ment.

20. Selector valve (272ZA) Connects unmonitored fluid flow discharge to either supply/return adapter (532CG or 532CH) in main sink. Fluid returns through alternate port

21. Pressure gage (079KD) Displays high-pressure inlet pressure to servo valve (236BA)

22. Ball valve (202BA) Shuts off high-pressure cooling flow to heat exchanger (322CA)

23. Needle valve (242GF) Bleeds high-pressure inlet pressure to selector valve (272ZA)

Panel J (Figure 4-9)

1. Toggle valve (210CN) Bleeds air from low side of transducer (061HA)

2. Toggle valve (210CP) Bleeds air from high side of transducer (061HA)

3. Toggle valve (210CL) Bleeds air from low side of transducer (061PA)

4. Toggle valve (210CM) Bleeds air from high side of transducer (061PA)

5. Toggle valve (210CC) Bleeds air from low side of transducer (061UA)

6. Toggle valve (210CD) Bleeds air from high side of transducer (061UA)

7. Bleed flow indicator Displays air bubbles when either toggle valve (210CC or 210CD) (110AC) opens line from transducer (061UA)

8. Needle valve (242KA) Provides adjustment of air supply to adapters (533BA and 534AD) through needle valves (242KB and 242KC)

9. Needle valve (242KD) Provides adjustment of return discharge air from adapter (534AE)

10. Needle valve (242KC) Provides adjustment of air supply pressure to adapter (534AD)

11. Needle valve (242KE) Provides adjustment of return discharge air from adapter (534AE) to flame arrestor (463BB)

12. Adapter (539BA) Provides hose connection through needle valve (249LA) to transducer

(062LA)

13. Needle valve (249LA) Connects transducer (062LA) to adapter (539BA)

14. Adapter (539BP) Provides hose connection through needle valve (249LM) to high side of transducer (061HA)

15. Needle valve (249LM) Connects high side of transducer (061HA) to adapter (539BP)

16. Adapter (539BM) Provides hose connection through needle valve (249LP) to high side of transducer (061PA)

17. Needle valve (249LP) Connects high side of transducer (061PA) to adapter (539BM)

18. Adapter (539BD) Provides hose connection through needle valve (249LD) to high side of transducer (061UA)

19. Needle valve (249LD) Connects high side of transducer (061UA) to adapter (539BD)

4-5

Index No. Nomenclature Function

20. Adapter (539BE) Provides hose connection through needle valve (249LE) to low side of transducer (061UA)

21. Needle valve (249LE) Connects low side of transducer (061UA) to adapter (539BE)

22. Adapter (534AE) Provides hose connection for discharged air

23. Adapter (539BN) Provides hose connection through needle valve (249LQ) to low side of transducer (061PA)

24. Needle valve (249LQ) Connects low side of transducer (061PA) to adapter (539BN)

25. Adapter (539BQ) Provides hose connection through needle valve (249LN) to low side of transducer (061HA)

26. Needle valve (249LN) Connects low side of transducer (061HA) to adapter (539BQ)

27. Adapter (534AD) Provides hose connection for stage 5

28. Adapter (539BB) Provides hose connection through needle valve (249LB) to transducer (062QA), through ball valve (200LA) to transducer (069EA), and through gage saver (390EA) to transducer (062HA)

29. Needle valve (249LB) Connects transducers (062HA, 062QA, and 069EA) to adapter

(539BB)

30. Adapter (539BC) Provides hose connection through needle valve (249LC) to transducer (062QB), through ball valve (200LB) to transducer (062SB), and through gage saver (390EB) to transducer (062HB)

31. Needle valve (249LC) Connects transducers (062HB, 062QB, and 062SB) to adapter

(539BC)

32. Adapter (533BA) Provides hose connection for stage 9

33. Adapter (539BX) Provides hose connection through needle valve (249LT) to transducer

(062JB)

34. Needle valve (249LT) Connects transducer (062JB) to adapter (539BX)

35. Adapter (539BW) Provides hose connection through needle valve (249LS) to transducer

(062JA)

36. Needle valve (249LS) Connects transducer (062SA) to adapter (539BW)

37. Needle valve (242KB) Provides adjustment of air supply pressure to adapter (533BA)

38. Bleed flow indicator Displays air bubbles when toggle valve (210CQ) opens line from (110AJ) transducers (062HA, 062QA, and 069EA)

39. Bleed flow indicator Displays air bubbles when toggle valve (210CS) opens line from (110AL) transducers (062HB, 062QB, and 062SB)

40. Pressure regulator (292CA) Regulates 90-125 PSIG air supply pressure to adapters (533BA and

534AD)

41. Toggle valve (210CQ) Bleeds air from transducers (062HA, 062QA, and 069EA)

42. Toggle valve (210CS) Bleeds air from transducers (062HB, 062QB, and 062SB)

43. Bleed flow indicator Displays air bubbles when either toggle valve (210CL or 210CM) (110AG) opens line from transducer (061PA)

44. Bleed flow indicator Displays air bubbles when either toggle valve (210CN or 210CP) (110AH) opens line from transducer (061HA)

Panel K (Figure 4-10)

1. Blow gun (557BA) Air nozzle with 20-foot hose attached to hose reel (556BA)

Panel L (Figure 4-11)

1. X-Y recorder (708JA) Records excitation voltage versus actuator rod position curves during testing. Input from control system (735AA)

4-6

Index No. Nomenclature Function

2. Control system (735AA) Provides slew rate, excitation, and displays for IGV actuator opera-tion; provides input to X-Y recorder (708JA) for plotting demand voltage versus position and provides primary/secondary voltage data to digital multimeter (DMM) (655CA)

3. DMM (655CA) Displays linear variable differential transformer (LVDT) primary or secondary voltages from IGV actuator control box

4. Selector switch (738FA) Selects LVDT primary or secondary voltage from IGV actuator con-trol box for indication on DMM (655CA)

5. Phone jack (801SA) Provides communication link between remote electrical cabinet and test stand

6. Pushbutton switch (730BB) Provides for emergency shutdown of test stand. Removes 120-VAC power and disables all control circuits except to inside lights and fire protection system

7. Operator station (733CD) Controls 120-VAC power to control system (735AA), X-Y recorder (708JA), and DMM (655CA). Green lamp lights when power is ap-plied

8. Operator station (733CC) Controls 120-VAC power to boost pump (348EA). Green lamp lights when power is applied

9. Operator station (733CB) Controls 120-VAC power to low-pressure supply pump (349RA).

Green lamp lights when power is applied

10. Operator station (733CA) Controls 120-VAC power to control relays (711AA and 711AM) and 3-way valve (273PA). Green lamp lights when power is applied

11. Indicating lamp (814EA) Green lamp lights when facility exhaust blower power is on

12. Indicating lamp (814EB) Green lamp lights when time delay relay (710BA) has completed cycle purge

13. Indicating lamp (814EC) Green lamp lights when 120-VAC power for spray chamber (552KA) pump motor is turned on by motor starter switch (720CA) and control relay (711DA)

14. Switch (725AA) Provides 120-VAC control power to spray chamber (552KA)

Panel M (Figure 4-12)

1. Hydrometer (150BA) Displays specific gravity of fluid in system

4.3 THEORY OF OPERATION. • Proof-pressure circuit

• Metered return port circuits

The test stand tests engine fuel accessory components • Fluid return circuit (referred to in text as a UUT). The following paragraphs • IGVA control system (735AA) describe the theory of operation of the test stand systems.

4.5 FOUR-HUNDRED-GALLON FUEL TANKSee Figure 4-1 for locations of control panels. Refer to Chapter 6 for significant item number (SIN) locator table, (552DA).

wiring diagram, and schematics.

The 400-gallon fuel tank supplies calibrating fluid, MIL-C-

4.4 FUEL SYSTEM - THEORY OF OPERATION. 7024, for the system.

The fuel system consists of the following major compo- 4.6 FILLING AND VENTING.

nents and circuits with related piping and valves:

During normal operation with UUT connected to the test

• 400-gallon fuel tank (552DA) stand, fluid used in the system is replenished from the fuel

• Low-pressure circuit tank. The tank is filled manually by gravity flow through

• High-pressure circuit flash arrestor (508EA) or from a pressurized source through

• Heat exchangers the pressure fill service connection [bezel (414AA)], ball

• Spray chambers (552KA and 552KB) valve (204BA), and 10-micron filter (313EA). The tank is

4-7 vented to atmosphere through vent (508AA) on top of test 4.9 DRAINING.

stand.

Normal and emergency draining of 400-gallon fuel tank is

4.7 LEVEL INDICATION. as follows:

Level switch (724AA) for fuel tank is interlocked with 4.9.1 Normal draining is through 2-inch ball valve supply and boost pump motor circuits. If fluid level in tank (208BB). Opening this valve allows fluid to flow from 400-drops to below one-half full, the switch opens. This shuts gallon fuel tank to facility drain through a 4-inch drain port down test stand and lights LOW FUEL LEVEL 400 GAL [bezel (419FA)] on service connection panel.

RESERVOIR indicator on channel 13 of annunciator

4.9.2 Emergency draining of tank is through dump valve(734GA). Level gage (120CA) on top of tank allows visual (209JA). This valve is held in closed position by a cableinspection of fluid level.

and five thermosensors. The thermosensors open at 160°F.

4.8 TEMPERATURE CONTROL. Opening of any one thermosensor causes dump valve to open and dump all fluid in drain. Opening dump valve also

Fluid temperature is monitored by switch (722JA), set at 93 causes an internal switch to shut down test stand and light to 97°F. If temperature rises above this value, the switch FUEL DUMP 400 GAL RESERVOIR indicator on channel opens. This shuts down test stand and lights OVER TEM- 2 of annunciator.

PERATURE 400 GAL RESERVOIR indicator on channel 8 of annunciator.

4-8

LEGEND

1. Pressure Switch Panel 8. Panel G

2. Service Panel 9. Panel H

3. Panel N 10. Panel J

4. Panel R 11. Panel K

5. Panel S 12. Panel L

6. Panel E 13. Panel M

7. Panel F

Figure 4-1. Panel Locations

4-9

Figure 4-2. Panel N

4-10

Figure 4-3. Panel R

4-11

Figure 4-4. Panel S

4-12

Figure 4-5. Panel E

4-13

Figure 4-6. Panel F

4-14

Figure 4-7. Panel G

4-15

Figure 4-8. Panel H

4-16

Figure 4-9. Panel J

4-17

Figure 4-10. Panel K

4-18

Figure 4-11. Panel L

4-19

Figure 4-12. Panel M

4-20

Figure 4-13. Service Panel

4-21

Figure 4-14. Pressure Switch Panel

4-22

4.10 LOW-PRESSURE CIRCUIT. valve (242GA) provides additional control at low pressures. Output is controlled by the setting of air

Fluid flows from…